Battery Manufacturer Safety Benchmarking Study
ScottMadden partnered with a leading lithium-ion battery manufacturer to enhance its safety performance.
Challenge
A leading lithium-ion battery manufacturer sought to enhance its safety performance by benchmarking safety culture, training, technology adoption, and performance management against industry leaders. With a high-volume, 24/7 production environment, the focus was on reducing risk, improving training effectiveness, and leveraging innovation to drive safety excellence.
Process
- Industry Benchmarking: Assessed safety programs, training models, and technology use across battery, EV, and advanced manufacturing sectors
- Risk Identification: Evaluated key hazards, including thermal runaway, hazardous materials, ergonomics, and fire prevention
- Best Practice Adoption: Identified AI-driven risk assessment, predictive analytics, and immersive training solutions (video, AR/VR, digital twins, dojo scenario training) to enhance workforce safety
- Performance Optimization: Developed proactive risk assessment models (A3 problem-solving) and enhanced KPIs for better safety measurement
Result
- Comparative Safety Analysis: Provided a data-driven evaluation of safety performance relative to industry benchmarks
- Advanced Training Solutions: Recommended scalable, technology-enhanced learning methods to support a continuous manufacturing environment
- Proactive Risk Management: Introduced structured risk assessments, safety dojos, and AI-enabled monitoring to reduce high-risk incidents
- Enhanced KPI Framework: Developed leading and lagging indicators to drive continuous improvement and accountability
- Future-Ready Safety Strategy: Positioned the company to proactively mitigate safety risks, ensure compliance, and sustain operational excellence
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